By: Capt In Bok Lee, SMSgt Philip Barry, SMSgt Amanda Dennis,TSgt Daniel Kosty, Mr. Jason Harbeck, and Mr. Jacob Dolinger
Success in the Air Force depends on our Airmen’s ability to achieve air superiority and win any battle. This requires our Airmen to think bigger and innovate at a level that keeps our force competitive which is what Tesseract’s Aether Sprint competition aims to accomplish.
Tesseract is the Headquarters of the Air Force Logistics Office of Innovation (AF/A4L), focused on empowering Airmen, connecting ideas and resources, and accelerating combat-focused logistics innovation to enhance the Air Force’s agile combat support and mission generation capabilities.
Entering its fourth year, the Aether Sprint competition is designed to give all Airmen a voice in the future of their career fields and the Air Force. It is a competition-based platform, designed to accelerate Airmen problem-solving by providing a structured approach to identify, develop, and implement innovative solutions. Aether Sprint brings Airmen from various specialties together to tackle the Director of Logistics’ questions on specific challenges affecting the logistics enterprise.
The 2025 Aether Sprint competition kicked off in August 2024, with questions derived from CORONA and A4L Leadership. CORONA is a summit that provides DAF leaders with a forum to discuss global concerns and the Air Force’s operational strategy within the joint force. The Aether Sprint announcement is widely shared through Enterprise Task Management System and Tesseract social media platforms to ensure maximum outreach and participation. Participants from across the force can submit their innovative solutions through a detailed intake form located on Tesseract’s website.
Once the submission window closes, an initial feasibility check is done, and the team identifies any need for clarification. The semi-finalist selection process involves a comprehensive assessment of all potential submissions by a panel consisting of A4L Division Chiefs, Deputies, and Senior Enlisted Leaders. The criteria each project is assessed on includes urgency of the problem set, impact, and feasibility of the proposed solution and strategic alignment.
Lego Scrum is an agile exercise that encourages personnel to utilize Scrum techniques, 9 January 2025. Photo provided by the authors.
The eight semi-finalist teams were selected in late November 2024, and Tesseract worked closely with all eight teams to refine their problem statements, proposed solutions, and project plans. At the beginning of January 2025, Tesseract facilitated their organic “Build Your Own Adventure” (BYOA) workshop, a scrum, and design thinking course to guide Airmen through the project management phase of their innovation projects. The course equips them with essential education, skills, and tools they can leverage for their current initiatives and throughout their careers. At the conclusion of the BYOA workshop, the semi-finalist teams each give a presentation to the A4L Director and their panel of advisors. The thorough evaluation ensures the most effective solutions are implemented. Once the panel selects its finalists, Tesseract announces them via social media and the finalist teams receive $150,000 towards prototype development and/or field-testing initiatives while also engaging with senior leadership for continued support.
This year’s Aether Sprint finalists have developed practical solutions aimed at improving aircraft maintenance, sortie generation, and equipment sustainment to increase lethality. Each project reflects an understanding of operational constraints and a commitment to enhancing readiness across the Air Force.
The 2025 Aether Sprint Finalists are:
1) OmniSeal
2) Low Rollers
3) Ruggedized Versatile Diagnostic Automatic Test Stations
4) Realistic Composite Trainer
Innovators: TSgt Shane Strack, TSgt Darren Hernandez, SSgt Brendan Webb, and SrA Zachary Flores
Coach: MSgt Craig Buying
Summary:
OmniSeal is a 3D-printed, corrosion-resistant cap designed to address Foreign Object Debris (FOD) prevention and cross-contamination issues in aircraft and vehicle maintenance.
Challenge:
Current sealing methods, such as metal caps and plastic bags, are unreliable and create multiple consequences like corrosion, and can allow FOD to enter critical components during maintenance. Each consequence can lead to a cascade of impacts to include increased maintenance and downtime, reducing overall mission capability.
Solution:
Image Above: A collection of 3D-printed prototypes, a universal solution designed to seal various
aircraft and vehicle components, showcased prior to field testing. (Photo by Shane Strack)
OmniSeal addresses this by providing a reliable, reusable alternative that can be produced on-site, reducing reliance on supply chains and decreasing maintenance time by 67%. OmniSeal takes an organic approach to solving maintenance leaks, using 3-D printed Thermoplastic Polyurethane (TPU) caps that are chemical resistant. These caps are designed to protect equipment from electrostatic discharge and reduce contamination. They have passed a 30-day chemical submersion test. These seal caps are produced organically from 3-D materials, resulting in a low cost of $3.28 per set, and enabling rapid production. Compared to existing sets, the 18th Equipment Maintenance Squadron reduced inventory costs from $1665 to $492 by replacing 750 traditional caps with 5 OmniSeal sizes.
Key Benefits:
Universal Fit: Ribbed, conical design adapts to air, fuel, oil, and hydraulic systems across various platforms.
Durable Materials: TPU ensures electrostatic discharge protection, resistance to extreme conditions, and extended component life.
Portable Manufacturing: Maintenance teams can 3D-print OmniSeal seals in real-time, eliminating reliance on traditional supply chains.
Path Forward:
The goal is to standardize OmniSeal, with orderable items through DoD supply chains, and incorporated into relevant Technical Orders across all services. The team envisions both 3D printing and injection molding as scalable production methods, depending on the operational environment. A patent request has been submitted, and the product will ideally be produced both on-site and through centralized supply facilities.
Demonstrating a real-world application during early testing at 18 EMS. The design offers universal fit and debris protection across various ports and openings. (Photo by TSgt Shane Strack)
Innovators: TSgt Seth Tessay, TSgt Brian Muehling, MSgt Robert Paradis, and SSgt Michael Kazy Garey
Coach: SSgt Joshua Nash
Summary:
Low Rolling Resistance (LRR) tires are installed onto specific and appropriate Aerospace Ground Equipment (AGE) to replace pneumatic style tires and put into operations across flightline and back shop maintenance settings.
Trelleborg Tires are a lowresistance rolling tire that is under consideration for AF AGE applications. (Photo sample by Trelleborg Tires USA)
Challenge:
AGE, such as -86 generators, often require over 250 pounds of lateral force to move just one inch, typically a two-person job. In time sensitive and austere environments, fluctuating manning levels can leave this burden on a single Airman, increasing fatigue and risking mission delays.
Solution:
LRR tires reduce the force required to maneuver and are easier to install than currently used split-rim pneumatic tires. Once implemented, these tires will require minimal maintenance. Additionally, LRR tires cut the required 250 pounds of lateral force in half. This is a game changer for sortie generation in a time sensitive combat setting where every second matters.
Key Benefits:
Cutting Force Requirements: Field tests show LRR tires reduce the required force by 50%, turning a two-person task into a one-person operation.
Enhancing Efficiency: LRR tires extend battery life for future electric tow vehicles and improve fuel efficiency for the current bobtail fleet by up to 10%.
Easy Integration: LRR tire and hub assemblies are easier to install than traditional pneumatic tires and require minimal maintenance.
An Airman demonstrating the ease of pushing AGE with the low resistance tires installed. (Photo by TSgt Seth Tessay)
Path Forward:
The team is seeking engineering authority to retrofit LRR tires on existing AGE carts, enabling enterprise-wide distribution. Field testing has yielded positive feedback from Precision Measurement Equipment Laboratory specialists and aircraft maintainers, demonstrating the real-world impact of this innovation.
Innovators: Braden Mulvey, Kimberly Mullins, Todd Oldham, Justin Shafer, William Adams, Sam Sheppard, Brian Crosby, Cody Giddens, Caleb Howell, and Mat Mosley
Coach: MSgt Christopher Stoller
Summary:
The portable, ruggedized VDATS increases aircraft availability while reducing weight, footprint, and lifecycle costs. It also improves adaptability for deployment and enhances operational flexibility.
Challenge:
The current VDATS system is extensive, standalone, and non-portable, limiting its deployment to depot locations and increasing aircraft downtime. Key issues include:
- Single points of failure at depot facilities
- Time-consuming back-and-forth shipment of components for diagnostics and repair
- Increased costs due to inefficiencies in repair processes
Solution:
Develop a new ruggedized portable configuration of the VDATS that will be multi-purpose, reduce weight, footprint, lifecycle cost, and optimize organic capabilities, resulting in improved adaptability, deployability, and operational flexibility enabling depot-level maintenance in a contested environment.
Preliminary design concepts for a portable VDATS. (Photos by Ms. Kimberly Mullins and Mr. Sam Sheppard)
Key Benefits:
Footprint Reduction: From large, stationary, isolated tester to portable, rugged tester.
Weight/Size Reduction: Establish portability.
Life Cycle Sustainment Savings: 100% organic sustainment.
Cost savings: Eliminate shipping for 41 National Stock Numbers, ~750 non-mission capable/failures by repairing in the Area of Responsibility (AOR).
Time Savings/ Increased Aircraft Availability: Reduce number of assets returned to Depot. Allow depot level repair in Theater/AOR. Eliminates up to 8 weeks round trip shipping. Increase aircraft and asset operational availability. Reduce mean time between failures. Decrease repair turnaround time.
Path Forward:
Seeking funding for development and deployment of portable VDATS. Policy modification is needed to define a new class of Enterprise-level testers that can be Centralized Asset Management (CAM) funded. Currently, depot-only testers cannot be sustained with CAM funds because they are supported through capital funded assets. If the tester will support more than the depot, then the Special Program Office will need capability to support CAM funds.
Innovators: SSgt Gregory Collins, SSgt Caleb Overby, TSgt Brandon Cummings, MSgt Emil Wodicka, MSgt Kalib McBride
Coaches: MSgt Emil Wodicka and MSgt Kalib McBride
Summary:
This RCT provides realistic F-35 aircraft structures for technicians to practice drilling, minimizing accidental aircraft damage and downtime.
Challenge:
Current training aids in the F-35 curriculum provide inadequate hands-on training that leave F-35 Low Observable technicians at risk of damaging aircraft structures, delaying sortie generation timelines, and impacting mission readiness. The 48th Fighter Wing loses 90 days of aircraft availability annually due to avoidable drill mishaps.
Solution:
Innovators are working with the Advanced Composites Lab at Hill AFB to produce a realistic training aid that replicates the curvature F-35 maintainers work on in the field.
Conceptual designs of the Realistic Composite Trainer. (Photos by MSgt Emil Wodicka)
Key Benefits:
Minimize Aircraft Downtime: Improved training reduces mis-drill damage, saving F-35 units significant time and resources.
Enhance Sortie Generation: Technicians gain the skills needed to complete panel fastening operations accurately and efficiently, improving mission readiness timelines.
Scalable Impact: Once proven, this solution can be expanded across the entire F-35 fleet, including F-35s for NATO allies, amplifying its global reach.
Path Forward:
Design and manufacture composite training panels with the Advanced Composite Lab at Hill AFB and F-35 Joint Program Office. Deliver training to technicians through the 372nd Training Squadron Field Training Detachment, starting with the 48 FW. Scale the system across other F-35 training squadrons for broader adoption.
ABOUT THE AUTHORS:
Concept Integration Branch, Tesseract “The Air Force Logistics Office of Innovation,” Headquarters Air Force Logistics Directorate. The Concept Integration Branch manages a portfolio of over 80 A4 innovative projects generated by tactical-level Airmen across multiple domains. They are responsible for empowering Airmen to innovate, connecting innovators to resources for development, scaling and sustainment of their ideas, and accelerating their initiatives to ensure their concepts are realized at the speed of relevance.
Capt In Bok Lee is a Logistics Readiness Officer, currently serving as the Branch Chief.
SMSgt Philip Barry is a Material Management Superintendent, currently serving as a Senior Program Manager.
SMSgt Amanda Dennis is an Accessories Superintendent, currently serving as a Senior Program Manager.
TSgt Daniel Kosty is a C-17 Flying Crew Chief, currently serving as a Senior Program Manager.
Mr. Jason Harbeck, Civilian, serving as a Program Analyst and Acquisition Strategist.
Mr. Jacob Dolinger, IBM Contractor, serving as a Program Manager.
The views expressed in this article are those of the authors and do not necessarily reflect the official policy or position of the Air Force, the Department of Defense, or the US Government.